Enhancing Powder Performance with Agglomeration

Agglomeration isn’t just about making powders easier to handle, it actively increases the value of the product. By transforming fine, dusty particles into uniform, free-flowing granules with improved solubility, flowability, and packaging efficiency, you’re creating a premium-grade powder that delivers better performance for users. In many industries, these enhanced properties translate directly into higher product quality, stronger brand reputation, and increased market competitiveness. 

The Process 

The product first undergoes the initial spray drying process, where hot air rapidly evaporates moisture from the droplets, transforming them into dry particles. However, some of these particles may be extremely fine and undesirable for the final product. Rather than being discarded, these fine particles are separated from the main product stream using cyclones.

The separated fines are then conveyed and reintroduced into the center of the spray into the drying chamber. When a wet droplet collides with the dry fines, the fines adhere to the droplet's surface, forming a larger agglomerated particle. This agglomeration process continues until the particles reach the desired size and moisture content. 

The process results in a final product with improved properties such as enhanced flowability, better solubility, and reduced dust formation. 

Why Agglomerate?  

During spray drying, the initial particles that form are often extremely fine, lightweight, and inconsistent making them prone to dusting, poor flow, and handling challenges. These characteristics can cause problems in downstream processing, packaging, and end use. 

Agglomeration solves these issues by encouraging these fine particles to bind together into larger, more uniform, and porous granules. This transformation improves flowability, enhances solubility, reduces dust, and ensures more consistent product performance across a wide range of applications. 

Benefits of Agglomeration in Spray Drying 

• Improved Handling and Flowability 

  • Fine powders can cause clogging, sticking, and inconsistent flow in processing lines. Agglomeration forms larger, more robust particles with improved flow characteristics, making them easier to transport, dose, and package. 

• Enhanced Solubility & Reconstitution 

  • Agglomerated powders have a porous structure with a greater overall surface area compared to dense, individual particles. This increased surface area allows water to penetrate more quickly, improving wetting, sinking, and dissolving properties. The result is a powder that reconstitutes faster and more uniformly, ideal for instant beverages, nutritional powders, and other products that need quick, consistent dissolution. 

• Reduced Dusting & Higher Yields 

  • In spray drying, fine particles can easily become airborne, ending up in dust collection systems or lost to the surrounding atmosphere. Agglomeration binds these fines into larger granules that stay in the product stream, reducing dusting and increasing yields.  

• Controlled Particle Size Distribution 

  • Agglomeration enables tight control over final particle size, allowing manufacturers to meet strict specifications for different applications. 

Products ideal for Agglomeration 

• Foods such as instant coffee, tea, cocoa, and protein powders 

• Dairy products 

• pharmaceuticals 

  
  

Final Thoughts 

By incorporating agglomeration into your spray drying process, you’re not just improving handling, you’re creating a higher-value powder that meets demanding customer expectations and stands out in the marketplace. Whether you’re producing instant food or diary mixes or pharmaceutical powders, integrating agglomeration into your spray drying process can give your company higher yields and production efficiency. 

Interested in improving your powder products? Contact us to learn how we can help you integrate agglomeration into your spray drying system. 

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